Smith Cast Iron Boilers GT Series manual

MODEL GT SERIES INST ALLA TION, OPERA TING AND MAINTENANCE MANU AL Modulating, Direct V ent, Gas-Fired Condensing Boilers Natural Or Propane 150,000 to 399,000 Btuh Input GTIOM-3 gama ENERGY ST AR ENERGY ST AR Do not store or use gasoline or other fl ammable v apor s and liquids in the vicinity of this or any other appliance. WHA T T O DO IF Y OU [...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS Pa g e 2 CONTENTS Bef ore Y ou Star t ................................................. page 2 Boiler Ratings & Capacities ............................... page 2 Boiler Location ................................................... page 3 Clearances to Comb ustible Construction .......... page 3 Combu[...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS P age 3 W ARNING: At elevations greater than 2000 ft, 660 m , the combustion of the GT must be c hecked with a calibrated combustion anal yzer to ensure safe and reliable operation. Consult the Operating Instructions Section for instructions on adjusting the input to pro vide proper operation. Failure t[...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS Pa g e 4 One of the f ollowing materials is to be used f or the air intake pipe: • GT -150 & 200: 3 in , 76 mm , PVC Sch.40 pipe or Galvaniz ed Steel pipe. • GT -400: 4 in , 102 mm or 6 in 152 mm , PVC Sch.40 pipe or Galvaniz ed Steel pipe. See T able 2 f or the maximum equiv alent air intake sy[...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS P age 5 The GT condensing gas boiler is a high efficiency boiler utilizing induced power v enting. It is designed to be vented directly to the outdoors using the v enting methods and materials detailed in this section. The vent system m ust be both gas tight and water tight. All horizontal vent piping m[...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS Pa g e 6 The vent terminal shall not ter minate: • Directly abov e a pav ed side walk or a pa v ed drive-w a y that is located between two b uildings, and that ser v es both buildings; • Less than 7 ft , 2.1 m abov e grade where located adjacent to a pav ed dr iv ewa y or public walkw ay . • Withi[...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS P age 7 When penetrating an outside wall the air intak e and vent pipes must be constrained as sho wn in Figure 6. The openings through which the air intake and v ent pipes pass must be properly sealed to prev ent products of combustion from entering the building. W ARNING: Failure to properl y install [...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS Pa g e 8 Figure 9 - External Air Intake and V ent Systems The debris screens provided with the boiler must be installed in both the air intake and v ent ter minals. Install the screens in the outer most opening then glue a 1 in , 25 mm length of pipe into the opening to retain them, Figure 10. Figure 10[...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS P age 9 Figure 13 - W all P enetration Detail The debris screen provided with the boiler must be installed in the concentric ter minal as shown in Figure 14. Figure 14 - Debris Screen Installation VER TICAL DIRECT VENT SYSTEMS Read the inf ormation in the GENERAL VENTING GUIDELINES section bef ore proce[...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS P age 10 Figure 18 - Multiple Concentric Through the Roof CONDENSA TE DRAIN W ARNING: The condensate siphon m ust be connected to the boiler per the follo wing instructions or combustion gases will enter the room. This can result in excessive levels of carbon mono xide which can cause se vere personal i[...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS P age 11 The f ollowing are important r ules that must be f ollowed when constructing the condensate system: 1 . Connect the condensate trap to the drain using 1/2 in , 13 mm , silicone, rubber , reinf orced nylon, or PEX tubing. Long runs must be pr operly pitched and supported to prevent blocka g e. 2[...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS P age 12 Understand and f ollow the plumbing requirements provided in this section. K eep ser viceability in mind when installing plumbing around the boiler cabinetr y . Install fi ttings that will allow the system to be fl ushed if needed during annual check-ups . Add an inhibitor to the system water[...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS P age 13 T ab le 3 - Recommended Primar y and Indirect Loop Cir culators Minimum Max. T emp. Minimum Primary & Restriction Flow Rise Indirect Pump Size Model Head Loss GPM , L/s °F , °C B&G Grundfos T aco GT -150 7 ft at 6 GPM , 2.1 m at 0.4 L/s 6 , 0.4 45 , 25 NRF-33 UP 26-64 0010 GT -200 10 [...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS P age 14 Air V ent Union Automatic Thermometer Pressu re Relief V a lve Reducing Check V a lve Pressu re Pump Ball Valve Gate V a lve Backflow-Prevention Device Drai n Valve (Typ.) Heating Load Valve Differential Pressure Bypass V a lve Spiro trap Fine Particulate Separa tor Figure 23 - Single Boiler wi[...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS P age 15 Figure 24 - Multiple Boiler Installation NO TES: 1. All piping and pumps must be suppor ted so that no loads or stresses are applied to boiler heat e xchanger. T o make boiler ser vice easy use Unions or fl e xible Vibration Isolation Kit. 2. This boiler is provided with a 1/8" v ent that[...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS P age 16 Air V ent Automatic Check Valve Pump Ball Valve Drain Valv e (Typ.) Heating Load Differenti al Press ure Bypass Val ve Zone Valve Expansio n Ta n k Spirotrap Fine Part icul ate Separator Figure 25 - Multiple Zones Using Circulator s NO TES: 1. All piping and pumps must be suppor ted so that no [...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS P age 17 Air V ent Automatic Check Valve Pump Ball Valve Drain Valv e (Typ.) Heating Load Differenti al Press ure Bypass Val ve Zone Valve Expansio n Ta n k Spirotrap Fine Part icul ate Separator Figure 26 - Multiple Zones V alves with Bypass V alve Note: V elocity noise may be a prob lem when the entir[...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS P age 18 Saf e lighting and other perf ormance cr iteria were met with the gas manif old and control assembly pro vided on the boiler when the boiler underwent tests specifi ed in ANSI Z21.13/CSA 4.9. All gas connections MUST be leak tested bef ore putting the boiler into operation. W ARNING: Never use[...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS P age 19 ELECTRICAL WIRING CA UTION: Label all wires prior to disconnection when servicing controls. Wiring err ors can cause improper and danger ous operation! The electrical connections to this boiler must be made in accordance with all applicable local codes and the latest re vision of the National E[...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS P age 20 Multiple 4 Wire Zone V alves Figure 30 shows the basic multiple z oned system uses nor mally closed f our (4) wire zone v alv es. This wiring system is used with the piping shown in Figure 26. When there is a call f or heat the room thermostat closes the circuit to the zone v alve motor , thus [...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS P age 21 Figure 30 - Multiple 4 Wire Zone V alves[...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS P age 22 Figure 31 - Multiple Zones w/ T aco V alve Controller , Models ZVC403 to ZVC 406[...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS P age 23 Multiple Zone Pump Controller Models T aco SR504, Argo ARM 861 Series Figure 32 shows the basic multiple z oned system using circulating pumps. This wiring system is used with the piping as shown in Figures 25. When there is a call f or heat the room thermostat closes the circuit between the TT[...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS P age 24 Figure 33 - Boiler Ladder Diagram[...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS P age 25 Figure 34 - Boiler Connection Diagram[...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS P age 26 Figure 35 - Con ventional Mode Operation Char t T -C & A-C Open T -C Closed & A-C open T -C Closed & A-C Closed T -C Open & A-C Closed Condition Standby Heating Only Domestic Only Domestic Only Set P oint — HI L0 L0 Burner On — HI - DIF LO-10 LO-10 Burner Off — HI + 10 200[...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS P age 27 Figure 38 - Input Con version Chart Setting Sentry 2100T control Programming is accomplished b y a ser ies of three push buttons located on the bottom side of the control. T o enter the programming mode , press the function key once, “R UN” should be display ed on the screen. T o scroll thr[...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS P age 28 Determining Reset T emperature HI Calc Once the Sentr y 2100T control identifi es the presence of a good outdoor sensor , the control will automatically reduce the HI setting based upon the outdoor temperature. For e xample, if Hi = 200°F , 93°C , RES = 70°F , 21°C and the Air T emperature[...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS P age 29 BOILER SET UP NO TE: Bef ore star ting the boiler , turn off the electrical supply going to it. Make sure that gas is av ailable at the gas valve inlet. Open the valves in the hot water return and supply piping. Failure to take these precautions will prevent the boiler fr om operation properl y[...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS P age 30 The gas supply pressure to the boiler while running at maximum rate m ust be between 4 to 9 in , 102 to 229 mm , W .C . f or natural gas installations; 9 to 12 in , 229 to 305 mm , W .C . f or propane installations. This pressure can be measured on the gas valv e using a manometer , Figure 41 o[...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS P age 31 Figure 43 - Operational Flow Chart Displays version t2.0 or t4.0 Awaitin g Input Sentry 2100 Sentry 2100 Sentry 2100 Fan to SFS (75) Sentry 2100 Error ASO Powe r to ign itor 120v from S 1 Powe r to Ga s valve Flame Probe Signal <1 mi croA Sentry 2100 Modulates fan based upon setpoint and pro[...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS P age 32 OPERA TING INSTRUCTIONS FOR Y OUR SAFETY READ BEFORE OPERA TING W ARNING: If you do not f ollow these instructions e xactly , a fi re or explosion ma y result causing property damage, personal injury or loss of life. A. This appliance does not hav e a pilot. It is equipped with an ignition de [...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS P age 33 Gas Pressure Adjustment Optimum results are obtained when the boiler is operated at its full input rating. If adjustment is necessary the f ollowing steps m ust be f ollow ed: 1. Connect a fl ue gas analyz er to the vent pipe. 2 . Rotate the input adjustment screw cloc kwise to decrease the ma[...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS P age 34 BOILER MAINTENANCE The boiler should be cleaned and inspected once a year , bef ore each heating season. CA UTION: Servicing, inspection and adjustment must be done b y a trained technician in accordance with all applicable local and national codes. Improper servicing or adjustment could damage[...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS P age 35 Aquastat High Limit The aquastat high limit controls the maximum water temperature in the boiler . If the water temper ature reaches the set temperature bef ore the demand for heat has been met, the aquastat high limit should shut the burners off. The outlet water temperature should ne ver e xc[...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS P age 36 1. Check to see if water is dripping on the sensor . 2. Reduce the Hi setting (and/or) ensure that there is proper water circulation in the system. Check wiring Check wiring. (Note: ER3 will be displa yed if temper ature sensed is less then 32°F , 0°C .) Note: If problem is corrected b y rese[...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS P age 37 This is displa yed when the boiler is e xpecting the air s witch to be closed by a diff erential pressure generated when the combustion b lower turns on. It can occur momentarily dur ing normal operation. A problem is indicated when ASO is displa yed contin uously . This is displa yed when the [...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS P age 38 Prob lem Detected Prob lem Solution This de vice protects the integrity of the plastic venting material. If the temperature of the fl ue gases e xceeds 225°F , 107°C , the limit will cut power to the control. Blocked internal tubes can increase the stack temper ature to an unacceptable le ve[...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS P age 39 Prob lem Detected Prob lem Solution Check f or voltage at the wires going to the A-C-T ter minals of the Boiler . Check the magnitude of the line v oltage power supply . Check the Amp dr aw of output C1 and Ap (max 3 Amp). Check the Amp dr aw of control on start-up (max 6 Amps) Contact Smith. C[...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS P age 40 The f ollowing are the thermister cur v es f or diagnosing the water and outdoor air sensors . 1 . Measure the resistance of the thermister when disconnected. 2. Using the appropr iate char t, fi nd the resistance and mov e ver tically f or the water probe or horizontally f or the air probe un[...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS P age 41 Item Part Number Description 1 GT -82657 Premix burner , 135.8 – 150 Only 1 GT -82658 Premix burner , 200.6 – 200 Only 1A GT -82761 Premix Burner Gasket 2 GT -82457 T ransf or mer , 24V 3 GT -82013 Sentr y 2100 4 GT -82052 Blow er #RG130 – 150 Only 4 GT -82661 Blow er #RG148/1200 – 200 [...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS P age 42 REPLA CEMENT P ARTS LIST Replacement par ts are av ailable from y our stocking wholesaler . Homeo wners must contact their local installer or wholesaler . Figure 49 - Replacement P arts Exploded View - Model GT400 Item Part Number Description 1 GT -83173 Premix Burner (For 400) 1A GT -82761 Pre[...]

GT INST ALLA TION AND OPERA TION INSTRUCTIONS P age 43[...]

WESTCAST , INC. 260 NORTH ELM STREET WESTFIELD, MA 01085 TEL. (413) 562-9631 F AX (413) 562-3799[...]